Formless installation of materials lifters and kiln lining

ABSTRACT

The disclosure concerns apparatus and methods enabling rapid installation of lining including brickwork in a kiln, and without forms.

United States Patent Inventor George F. Olsen Colton, Calif.

Aug. 7, 1969 July 13, 1972 Calliornia Portland Cement Company Los Angeles, Calif.

Appl. No. Filed Patented Assignee FORMLESS INSTALLATION OF MATERIALS LIFTERS AND KILN LINING 8 Claims, 5 Drawing Figs.

[1.8. CI 263/33 R, 110/1 A, 263/46 lnt. Cl F27b 7/20 Field oISelrch 263/33,46; 110/1 A; 264/30 [56] References Cited UNITED STATES PATENTS 1,882,421 10/1932 Hedrick 263/33 1,920,677 8/1933 Burke 263/33 1,953,856 4/1934 Heyman 263/33 3,350,085 10/1967 Over 263/46 X 3,362,698 1/1968 Cerny et al. 263/33 3,445,099 5/1969 Olsen et a1. l, 263/33 Primary Examiner-John J. Carnby Attorney-White & l-laefliger ABSTRACT: The disclosure concerns apparatus and methods enabling rapid installation of lining including brickwork in a kiln, and without forms,

FORMLESS INSTALLATION OF MATERIALS LIFTERS AND KILN LINING BACKGROUND OF THE INVENTION This invention relates generally to lining rotary kilns, and more particularly concerns the installation of such lining including brickwork without the use of forms.

The operation of rotary kilns typically includes the feeding of materials into the kiln at one end followed by slow travel of those materials lengthwise as the kiln rotates, the materials being subjected to heat treatment therein. Such gases may for example be introduced into the opposite end of the kiln and repeatedly contact the materials as they are agitated with cascading in the kiln interior; and, in the production Portland Cement, the calcareous materials may slowly travel toward the burner at the exit end of the kiln, and the temperature of such materials is raised to an extent necessary to produce an exothermic reaction with consequent production of clinker.

Kilns as described are commonly lined with refractory bricks or blocks characterized by their heat resistant properties; and, such lining are replaced at intervals. At the present time it is accepted practice to lay the bricks using forms to hold them in place during installation. For example, the bricks may be placed on an arched wooden form which supports the bricks in the upper interior of the kiln; alternatively, the bricks may be laid on the kiln surface at the lower interior and maintained in place by wooden shoring and hydraulic jacks as the kiln is rotated during the installation process. Only after laying of the bricks is completed are the forms removed. See US. Pat. No. 3,445,099.

Both practices are time consuming and the forms severely restrict the work area, entailing excessive labor and expensive,

SUMMARY OF THE INVENTION It is a major object of the invention to overcome the above as well as other problems encountered in lining kilns, by means of method and apparatus enabling formless installation of lining including brickwork.

As regards method, the provision of a rotary kiln with refractory structure acting to line the kiln shell includes the steps of installing in the kiln elongated refractory beam members to be spaced about the kiln axis and to extend generally lengthwise of that axis; and installing refractory lining including brickwork in the kiln to cover inwardly exposed extent of the shell inner surface and so as to have arched configuration between successive of the members, thereby to be supported against inward displacement or dislodgement toward the kiln interior during rotation. As will appear, the lining installation may advantageously include laying the brickwork between successive of the refractory members as the kiln is rotated or located to position the members at levels lower than the inclined kiln axis. Preliminarily, the members may be formed outside the kiln and transported into the kiln for attachment to the shell, whereby the fixed members lock the brickwork against inward dislodgement as the kiln rotates during and after the installation.

As regards the apparatus of the invention, it may be considered to include, basically; elongated refractory beam members installed in the kiln to extend generally endwise therein and proximate the shell inner surface, the members being spaced about the kiln axis; and, refractory lining installed in the kiln to cover inwardly exposed extent of the shell inner surface, the lining including brickwork installed between successive of beam members in the direction of kiln rotation and the lining having arched configuration, so as to be supported by the successive beam members against dislodgement toward the kiln interior. Typically, the beam members may have opposite sides that taper toward the kiln interior, the lining fitting those opposite sides to block displacement of the members toward the kiln interior. Further, the lining may advantageously include cast retainers located between those opposite sides of the members and the brickwork so as to achieve the interlock relationship to best advantage.

Additional objects and advantages include th provision of members which protrude toward the kiln interior relative to the lining in order to lift and tumble the kiln treated materials in response to kiln rotation; the provision of members whose inward facing surfaces define a cylinder approximately tangent to the inner surface of the lining; the provision of members which protrude laterally as well as inwardly for purposes as will appear; and the provision of metallic reinforcement and attachment straps in association with the members.

These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following detailed description of the drawings, in which:

BRIEF DESCRIPTION OF THE DRAWINGS DESCRIPTION OF PREFERRED EMBODIMENT Referring to FIG. 1, an elongated kiln is shown at 10 as having a tubular metallic outer shell 11, with a burner apparatus 12 at the hooded exit end 13 of the kiln. Calcareous materials 14 are introduced at the entrance end 15 of the kiln, to be slowly traveled lengthwise leftwardly toward end 13 in response to kiln rotation, the materials receiving heat transfer from the hot gases traveling rightwardly in the kiln interior. Elongated refractory beam members such as lifters 16 may be used anywhere in the kiln, and in the example shown they extend to the right of the zone 17 wherein the materials reach their highest temperature, prior to exit as clinker 18.

As better seen in FIG. 2, the lifter members are installed spaced about the kiln axis 19, and extend endwise, lengthwise of the kiln, so as to effect lifting and cascading of the materials as indicated at 14a as the kiln rotates. Note that the lifters have opposite sides 20 which taper inwardly toward the interior ofthe kiln, with protuberance beyond the kiln lining 21.

The refractory lining'is installed in the kiln to cover inwardly exposed extent of the shell inner surface. In this regard, the lining includes blocks I00 forming brickwork installed between successive of the beam members 16 in the direction of kiln rotation. Further, the installed brickwork lining has arched configuration, as for example is seen at 101 so as to be supported by the successive beam members 16 against displacement (such as gravitational dislodgement) toward the kiln interior. As seen in FIG. 2, refractory retainers 103 are cast to be located between opposite sides 20 of the members and the lining bricks in such manner as to become part of the lining held against displacement toward the kiln interior. Accordingly, the lining including the brickwork may be easily and rapidly installed, without use of forms, between successive beam members to have the referred to arched configuration with opposite ends of the arch anchored (via beam members 16) to the shell 11.

Such anchoring may be advantageously effected by means of metallic elements 22 at the bases of the members, and described below in connection with the modified beam member seen in FIGS. 3 and 4.

Referring to FIG. 4, the modified beam members are formed outside the kiln, as by casting refractory material in appropriate molds or cavities. A refractory slurry suitable for casting may for example consist of a dry mix containing from ID to 40 percent by weight calcium aluminate cementitious agent, from 0 to 20 percent plasticizer such as pulverized clay or grog, and the remainder of the mix being calcined fire clay granules between 1 inch mesh and 65 mesh (Tyler screens),

together with sufficient water to give a casting consistency (i.e. from 8 percent to 15 percent of the slurry weight). Alternatively, the beam members may have the same composition as the bricks-Le. between 40 percent and 70 percent A1 or magnesite, depending upon refractory requirements. The casting is carried out in such manner in relation to a series of metallic (as for example stainless steel) elements generally indicated at 22 that the latter are spaced along the beam member. Those elements include certain anchor portions 220 embedded in the member and other base portions 22b extending at the undersides 23 of the beam members and projecting freely therefrom, as is clear from FIG. 4.

The anchor portions 22a may advantageously comprise corrugated strips connected to the base portions 221; and projecting upwardly throughout the major height of the beam member refractory. Successive anchor portions 22a along the member have their corrugations reversed, i.e. define planes which are out of lengthwise alignment in order to preclude problems of refractory cracking along the length of the beam member during use. Note that member 16a protrudes at 1105 along its length toward the kiln interior and inwardly relative to lining bricks 106 so as to lift the materials undergoing treatment in the rotating kiln. In addition, member 16a is forward to protrude laterally at 107 along its length toward the lining bricks, whereby the member has T-shaped configuration (inverted in H0. 3). Protruding portions correspond to the cast retainers 103 in FIG. 2, and interfit the bricks 106 at faces 108.

The member 1160 has integral metallic base portions 22b which project sidewardly at the bottom of the member in order to facilitate quick and secure attachment to the steel shell of the kiln, as by the welds indicated at 24. Spot welds may also be used. In this regard, the precast lifter members 16a may, after curing, be carried into the kiln and quickly attached to the shell at the lowermost position shown in FIG. 2, the kiln being indexed or rotated sufficiently for the attachment of the members in sequence. Additional anchor portions 22c (similar to anchor portions 22a) are embedded in the protuberant portions 107 of the member 160, and are attached to the base portions 22b at the metallic anchor.

Finally, FIG. illustrates the use of refractory beam members 16b like those members 16 seen in FIG. 2, but not protuberant toward the kiln interior relative to the cylinder defined by the inner surfaces of the lining bricks 100. Beam members 16b serve principally as a means to anchor the opposite ends of the brickwork arches in position.

Advantageous results afforded by the invention include: a considerable time saving (of the order of 50 percent) in laying rotary kiln bricks or blocks; the use of compatible composition precast beam members not only in kiln zones where alumina blocks are installed, but also in zones where basic bricks are required; the use of beam members as described as materials lifters and brick arch anchors, or simply as such anchors; advantageous interfitting support of the bricks with higher arch stability, through use of such beam members having precast surfaces of high quality; and the adaptation of such beam members to brickwork support in kilns of many different diameters; the number of beams merely being changed to meet the conditions encountered.

Iclaim:

1. In a rotary kiln having a tubular shell defining a central axis and adapted to receive materials to be subject to heat treatment within the kiln interior as the kiln rotates about said axis, the combination comprising a. multiple elongated refractory beam members each including refractory material precast and cured outside the kiln and thereafter installed in the kiln to extend generally endwise thereof and proximate the shell inner surface,

said members being spaced about said axis,

b. refractory lining installed in the kiln to cover inwardly exposed extent of said shell inner surface, the lining including brickwork installed between successive of said beam members in the direction of kiln rotation and the linin extending in retaining relation with said members and having arched configuration so as to be supported by said successive beam members against displacement toward the kiln interior, and

c. means attaching said members to the shell independently of said lining, said means including anchor portions embedded in said members and metallic straps extending transversely with respect to said members and having terminals underlapping said lining, said straps attached to the inner side of said shell.

2. The combination of claim 1 wherein the members each have opposite sides that taper toward the kiln interior and said lining fits said opposite sides to block displacement of the members toward the kiln interior.

3. The combination of claim 2 wherein the lining includes cast retainers located between said opposite sides and said brickwork.

t. The combination of claim 1 wherein said members protrude along their lengths toward the kiln interior and inwardly relative to the lining so as to lift said materials in response to kiln rotation.

5. In a rotary kiln having a shell and adapted to receive materials to be subject to heat treatment within the kiln interior as the kiln rotates about its axis, the combination comprising a. elongated refractory beam members installed in the kiln to extend generally endwise thereof and proximate the shell inner surface, said members being spaced about said axis,

b. refractory lining installed in the kiln to cover inwardly exposed extent of said shell inner surface, the lining including brickwork installed between successive of said beam members in the direction of kiln rotation and the lining having arched configuration so as to be supported by said successive beam members against displacement toward the kiln interior, and

c. said members having inwardly facing surfaces that define a cylinder substantially tangent to the inner surface of said lining.

6. The combination of claim 4 wherein said members also protrude laterally along their lengths toward the lining, whereby the members have T-shaped cross sections.

7. The method of providing a rotary kiln with refractory structure including brickwork acting to line the kiln shell, the kiln being tubular and defining a central axis, that includes a. forming outside the kiln multiple elongated beam members sized to be carried into and installed within the kiln with spacing about the kiln axis and to extend generally lengthwise of that axis,

b. installing said members in the kiln as aforesaid and with attachment to the kiln shell inner surface, and

c. installing refractory lining including brickwork in the kiln to cover inwardly exposed extent of the shell inner surface between said members and so as to have arched configuration between successive of said members and to be supported by said members against displacement toward the kiln interior during kiln rotation.

8. The method of claim 7 wherein said lining installation includes laying said brickwork between successive members with spacing from at least one member, and casting refractory material into said spacing to interfit between the bricks and the side ofsaid one member. I

UNITED STATES PATENT OFFICE 5 CERTIFICATE OF CORRECTION 5' Patent NO- 3 592 454 Dated 19 Invent0 George F Olsen 5 It is certified that error appears in the aboveidentified patent and that said Letters Patent are hereby corrected as shown below:

! Summary Page, at [45] "Patented July 13, 1972 should I read -Patented July 13, 1971-- Signed and sealed this 11th day of January 1972.

i f (SEAL) F! Attest FEDWAED M.FLlnlCH1iJl-l, JR. ROBERT GOTTSCHALK ljAttestin Officer Acting Commissioner' of Patents :ORM F o-1050 (10-69) USCOMM-DC e037e-s=eo Q U S, GOVERNMENY FRINTHG DFFICE' 1919 O3B5-334 

2. The combination of claim 1 wherein the members each have opposite sides that taper toward the kiln interior and said lining fits said opposite sides to block displacement of the members toward the kiln interior.
 3. The combination of claim 2 wherein the lining includes cast retainers located between said opposite sides and said brickwork.
 4. The combination of claim 1 wherein said members protrude along their lengths toward the kiln interior and inwardly relative to the lining so as to lift said materials in response to kiln rotation.
 5. In a rotary kiln having a shell and adapted to receive materials to be subject to heat treatment within the kiln interior as the kiln rotates about its axis, the combination comprising a. elongated refractory beam members installed in the kiln to extend generally endwise thereof and proximate the shell inner surface, said members being spaced about said axis, b. refractory lining installed in the kiln to cover inwardly exposed extent of said shell inner surface, the lining including brickwork installed between successive of said beam members in the direction of kiln rotation and the lining having arched configuration so as to be supported by said successive beam members against displacement toward the kiln interior, and c. said members having inwardly facing surfaces that define a cylinder substantially tangent to the inner surface of said lining.
 6. The combination of claim 4 wherein said members also protrude laterally along their lengths toward the lining, whereby the members have T-shaped cross sections.
 7. The method of providing a rotary kiln with refractory structure including brickwork acting to line the kiln shell, the kiln being tubular and defining a central axis, that includes a. forming outside the kiln multiple elongated beam members sized to be carried into and installed within the kiln with spacing about the kiln axis and to extend generally lengthwise of that axis, b. installing said members in the kiln as aforesaid and with attachment to the kiln shell inner surface, and c. installing refractory lining including brickwork in the kiln to cover inwardly exposed extent of the shell inner surface between said members and so as to havE arched configuration between successive of said members and to be supported by said members against displacement toward the kiln interior during kiln rotation.
 8. The method of claim 7 wherein said lining installation includes laying said brickwork between successive members with spacing from at least one member, and casting refractory material into said spacing to interfit between the bricks and the side of said one member. 